Apparatus, Systems and Methods for Sampling and Conditioning A Flluid

ABSTRACT

A system of sampling a fluid comprises a fluid separator having a central axis. The fluid separator includes an insulating sleeve. In addition the fluid separator includes a separator assembly coaxially disposed within the sleeve. Further, the fluid separator includes an annulus radially disposed between the sleeve and the separator assembly. The separator assembly includes a conduit, a support rod coaxially disposed within the conduit, and a plurality of separator members coupled to the support rod within the conduit.

CROSS-REFERENCE TO RELATED APPLICATIONS

Not applicable.

STATEMENT REGARDING FEDERALLY SPONSORED RESEARCH OR DEVELOPMENT

Not applicable.

BACKGROUND

1. Field of the Invention

The invention relates generally to analysis of sampled fluids. Moreparticularly, the invention relates to conditioning a sampledhydrocarbon fluid for prior to downstream analysis.

2. Background of the Technology

In the hydrocarbon processing industry, analytical instrumentation isemployed at various stages of processing to analyze the chemicalcomposition of the fluids being processed. Typically, theinstrumentation analyzes a small sample taken from a hydrocarbon fluidstream undergoing processing. However, prior to introducing the sampleto the analytical instrumentation, the sample must be “conditioned” toremove contaminates that may otherwise damage to the instrumentationand/or undesirably skew the analytical results such as product yieldresults (i.e., desired product volume produced per unit time). In somecases, plant operations may over-react or under-react to the inaccurateresults, potentially leading to higher operating cost.

Referring now to FIG. 1, a conventional system 10 for sampling a decokeor green oil fluid stream 15 during hydrocarbon cracking or pyrolysisoperations is schematically shown. System 10 includes a fluidconditioner 20 and analytical equipment 30 downstream from conditioner20. The bulk decoke or green oil (recycle gas) fluid stream 15 issampled and analyzed to provide insight into the cracking processing.For example, bulk decoke fluid stream 15 may be sampled and analyzed todetermine the yield of a desired product (e.g., volume of ethylene orpropylene being produced by the cracking process per unit time).

As shown in FIG. 1, a sample 16 is pulled from the bulk decoke fluidstream 15. When sample 16 is initially pulled from the process fluidstream 15, it typically comprises a mixture of a gas 17 to be analyzedand undesirable contaminants 18 such as water and/or relatively heavyhydrocarbons (i.e. C6 and heavier). Contaminants 18 can foul and/ordamage downstream fluid transport lines and analytical equipment 30. Inaddition, contaminants may negatively impact the accuracy of analyticalresults produced by analytical equipment 30. Consequently, sample 16 ispassed through fluid conditioner 20 before being passed to analyticalequipment 30. The goal of conditioner 20 is to remove the contaminants18 from sample 16 prior to analysis. Accordingly, conditioner 20separates sample 16 into contaminants 18, which are fed back to bulkfluid stream 15, and gas 17, which is passed on to analytical equipment30 for further analysis. Analytical equipment 30 analyzes gas 17 todetermine the yield rate 19 of gas 17, which is communicated to theplant operators. Once analyzed, gas 17 is fed back to bulk fluid stream15.

Most conventional sample conditioning devices (e.g., conditioner 20) areheat exchangers with manual controls. Such devices allow the relativelyhot sample fluid to pass through a cooled pipe that includes a pluralityof stacked stainless steel mesh pads. Due to the temperature of thecooled chamber, typically about 60° to 90° F., and the torturous path,defined by the mesh pads, that the sample must navigate through, some ofthe water and relatively heavy molecular weight components (i.e.,components with molecular weights greater than 86) in the sampled fluidwill decelerate, form into droplets on the mesh pads, and then fall backdown into the hydrocarbon process stream from which they came.

Maintenance of such conventional conditioning devices can be timeconsuming, labor intensive, and expensive. In particular, mostconventional conditioning devices require that the entire device beremoved from the pipe string within which it is disposed for service tobe performed. In addition, the total surface area provided by theplurality of mesh pads is usually only about 144 in.², which tends to bemore easily fouled. Further, most conventional conditioning devices mustbe visually inspected and monitored, and manually controlled. In otherwords, most conventional conditioning devices provide no externalinsight into the sampling process, the current sample temperature, thestatus of the conditioner, or the temperature of the cooling air in theconditioner, each of which may allow the plant operators to ascertainwhether the analytical data is valid or not.

Accordingly, there remains a need in the art for fluid sampling devices,systems, and methods that offered the potential for improved separationefficiency and insight into the fluid processing being monitored. Suchdevices and systems would be particularly well received if they could bemaintained with reduced effort and expense.

BRIEF SUMMARY OF THE DISCLOSURE

These and other needs in the art are addressed in one embodiment by afluid sampling system. In an embodiment, the system comprises a fluidseparator having a central axis. The separator includes an insulatingsleeve. In addition, the separator includes a separator assemblycoaxially disposed within the sleeve. Further, the separator includes anannulus radially disposed between the sleeve and the separator assembly.The separator assembly includes a conduit, a support rod coaxiallydisposed within the conduit, and a plurality of separator memberscoupled to the support rod within the conduit.

These and other needs in the art are addressed in another embodiment bya system for removing contaminants from a sample fluid. In anembodiment, the system comprises a fluid separator having a central axisand extending axially between an upper end and a lower end. The fluidseparator includes an insulating sleeve axially positioned between theupper end and the lower end. In addition, the fluid separator includes aseparator assembly coaxially disposed within the sleeve and extendingbetween the upper end and the lower end. The separator assembly includesan inlet and an outlet. Further, the fluid separator includes an annulusradially disposed between the sleeve and the separator assembly. Theannulus includes an inlet and an outlet. Still further, the fluidseparator includes a cooling device adapted to pump a cooling fluidthrough the inlet of the annulus. The system also comprises a monitoringand control system coupled to the fluid separator. The monitoring andcontrol system includes a first temperature sensor proximal the outletof the separator assembly. The first temperature sensor is adapted tomeasure the temperature of a fluid flowing through the outlet of theseparator assembly.

These and other needs in the art are addressed in another embodiment bymethod. In an embodiment, the method comprises (a) acquiring anunconditioned fluid sample from a bulk fluid stream. In addition, themethod comprises (b) providing a separator having a central axis. Theseparator includes an insulating sleeve, a conduit coaxially disposedwithin the insulating sleeve, an annulus radially disposed between theinsulating sleeve and the conduit, and a plurality of separator membersdisposed within the conduit. The conduit includes an inlet and an outletand is radially spaced apart from the insulating sleeve. Further, theannulus has an inlet. Further, the method comprises (c) flowing theunconditioned fluid sample through the inlet of the conduit. Stillfurther, the method comprises (d) flowing a cooling fluid through theinlet of the annulus. Moreover, the method comprises (e) separating acontaminant fluid from the unconditioned fluid sample in the separatorassembly to produce a conditioned sample fluid. In addition, the methodcomprises (f) flowing the conditioned fluid through the outlet of theconduit. Further, the method comprises (g) measuring the temperature ofthe conditioned sample fluid at the outlet of the conduit. The methodalso comprises (h) analyzing the conditioned fluid sample to estimate ayield rate for a product in the bulk fluid stream.

Thus, embodiments described herein comprise a combination of featuresand advantages intended to address various shortcomings associated withcertain prior devices, systems, and methods. The various characteristicsdescribed above, as well as other features, will be readily apparent tothose skilled in the art upon reading the following detaileddescription, and by referring to the accompanying drawings.

BRIEF DESCRIPTION OF THE DRAWINGS

For a detailed description of the preferred embodiments of theinvention, reference will now be made to the accompanying drawings inwhich:

FIG. 1 is a schematic view of a conventional system for sampling ahydrocarbon fluid stream;

FIG. 2 is a partial cross-sectional schematic view of an embodiment offluid sampling system in accordance with the principles describedherein;

FIG. 3 is a partial cross-sectional view of the fluid separator of FIG.2;

FIG. 4 is a cross-sectional view of the upper end of the fluid separatorof FIG. 2;

FIG. 5 is a cross-sectional view of the lower end of the fluid separatorof FIG. 2;

FIG. 6 is a cross-sectional view of an intermediate portion of the fluidseparator of FIG. 2;

FIG. 7 is a cross-sectional view of the separator assembly of FIG. 3;

FIG. 8 is a top view of a plate of the fluid separator of FIG. 3;

FIG. 9 is a cross-sectional view of the plate of FIG. 8 taken alongsection 8-8 of FIG. 8;

FIG. 10 is a top view of a baffle of the fluid separator of FIG. 3;

FIG. 11 is a cross-sectional view of the baffle of FIG. 10 taken alongsection 10-10 of FIG. 9;

FIG. 12 is a top view of a separator member of the fluid separator ofFIG. 3;

FIG. 13 is a cross-sectional view of the separator member of FIG. 12taken along section 12-12 of FIG. 12;

FIG. 14 is an enlarged top view of the upper gasket of FIG. 5; and

FIG. 15 is an enlarged top view of the lower gasket of FIG. 5.

DETAILED DESCRIPTION OF SOME OF THE PREFERRED EMBODIMENTS

The following discussion is directed to various embodiments of theinvention. Although one or more of these embodiments may be preferred,the embodiments disclosed should not be interpreted, or otherwise used,as limiting the scope of the disclosure, including the claims. Inaddition, one skilled in the art will understand that the followingdescription has broad application, and the discussion of any embodimentis meant only to be exemplary of that embodiment, and not intended tointimate that the scope of the disclosure, including the claims, islimited to that embodiment.

Certain terms are used throughout the following description and claimsto refer to particular features or components. As one skilled in the artwill appreciate, different persons may refer to the same feature orcomponent by different names. This document does not intend todistinguish between components or features that differ in name but notfunction. The drawing figures are not necessarily to scale. Certainfeatures and components herein may be shown exaggerated in scale or insomewhat schematic form and some details of conventional elements maynot be shown in interest of clarity and conciseness.

In the following discussion and in the claims, the terms “including” and“comprising” are used in an open-ended fashion, and thus should beinterpreted to mean “including, but not limited to . . . . ” Also, theterm “couple” or “couples” is intended to mean either an indirect ordirect connection. Thus, if a first device couples to a second device,that connection may be through a direct connection, or through anindirect connection via other devices, components, and connections. Inaddition, as used herein, the terms “axial” and “axially” generally meanalong or parallel to a central axis (e.g., central axis of a body or aport), while the terms “radial” and “radially” generally meanperpendicular to the central axis. For instance, an axial distancerefers to a distance measured along or parallel to the central axis, anda radial distance means a distance measured perpendicular to the centralaxis.

Referring now to FIG. 2, an embodiment of a fluid sampling system 100 isschematically shown. System 100 includes a fluid separator 200 and asample monitoring and control system 300 coupled to separator 200. InFIG. 2, fluid separator 200 is shown in front view and sample monitoringand control system 300 is shown in a schematic partial cross-sectionalview.

In general, fluid separator 200 separates a raw or unconditioned fluidsample 101 taken from a hydrocarbon or chemical processing operationinto contaminants 102 and a conditioned fluid sample 103 (i.e., a fluidsample that is substantially free of contaminants that may foul and/ordamage downstream equipment), which is passed to downstream analyticalequipment for further analysis. In other words, separator 200 conditionsthe raw fluid sample 101 for subsequent processing and analysis.Accordingly, separator 200 may also be referred to as a “fluidconditioner” or “fluid conditioning device.” Sample monitoring andcontrol module 300 measures multiple predetermined parameters associatedwith the sample separation process and controls the sample separationprocess within separator 200. As will be described in more detail below,module 300 may adjust the sample separating process within separator 200automatically based on the measured parameters (i.e., without humanintervention) and/or in response to input from a remote operator. Inpractice, a plurality of systems 100 may be employed in a chemical orhydrocarbon processing operation to sample fluid and condition thesampled fluids at different stages or locations along the processingoperations.

In the embodiments described herein, system 100 is employed to aid inthe sampling and analysis of a decoke fluid sample from a hydrocarboncracking operation to determine the ethylene and/or propylene yieldsduring the cracking operations. Thus, raw fluid sample 101 comprises anunconditioned decoke fluid sample taken from a bulk decoke fluid streamflowing through the hydrocarbon cracking equipment. The unconditioneddecoke fluid sample 101 typically comprises a mixture of contaminantssuch as water, relatively heavy hydrocarbons (i.e., hydrocarbonmolecules having six or more carbon atoms), small quantities ofparticulate matter, which can foul and/or damage downstream samplingequipment, and the relatively light hydrocarbons (i.e., hydrocarbonsmolecules having five or less carbon atoms) such as ethylene, propylene,methane, ethane, and propane. Accordingly, contaminants 102 comprisewater, relatively heavy hydrocarbons, and particulate matter;conditioned fluid sample 103 comprises a mixture of the relatively lighthydrocarbons as well as small amounts of other non-contaminating fluidsthat do not foul or damage downstream hardware. Thus, fluid separator200 receives unconditioned decoke fluid sample (i.e., unconditionedfluid sample 101), separates water, relatively heavy hydrocarbons, andparticulate matter (i.e., contaminants 102) from the unconditioneddecoke fluid sample, and outputs a mixture of the relatively lighthydrocarbons and small amount of other non-contaminating fluids (i.e.,conditioned fluid sample 103). Once separated, contaminants 102 areallowed to flow back into the bulk decoke fluid stream. Due to theelevated temperature of the bulk decoke fluid stream, the unconditionedfluid sample 101 is typically a relatively hot gas with some suspendedparticulate matter. As will be described in more detail below, duringconditioning with separator 200, unconditioned fluid sample 101 iscooled, and as a result, gaseous contaminants 102 such as water andrelatively heavy hydrocarbons phase change to liquid droplets thatcoalesce within separator 200. Although unconditioned fluid sample 101is cooled and gaseous contaminants 102 separate out in liquid form,conditioned fluid sample 103 remains a gas, albeit at a lowertemperature than the unconditioned fluid sample 101. Followingconditioning with separator 200, the conditioned fluid sample 103 maythen be passed downstream to analytical equipment to determine theethylene and/or propylene yields during the cracking operation. Byremoving contaminants 102 from the unconditioned fluid sample 101 toproduced conditioned sample 103, separator 200 offers the potential toreduce fouling and/or damage to downstream hardware by contaminants 102.

Referring now to FIGS. 2 and 3, fluid separator 200 has a central orlongitudinal axis 205 and extends axially between a first or lower end200 a and a second or upper end 200 b. In this embodiment, each end 200a, b comprises a mounting flange 202, 203, respectively. Lower flange202 couples fluid separator 200 to other device(s) and/or fluidconduit(s) positioned upstream of separator 200 relative to the flow ofunconditioned fluid sample 101, and upper flange 203 couples fluidseparator 200 to other device(s) and fluid conduit(s) positioneddownstream of fluid separator 200 relative to the flow of unconditionedfluid sample 101. In addition, fluid separator 200 includes a radiallyouter insulating sleeve 210 and a radially inner separator assembly 230coaxially disposed within sleeve 210.

Referring now to FIGS. 3-5, insulating sleeve 210 has a central orlongitudinal axis 215 coincident with axis 205 and extends axiallybetween a first or upper end 210 a proximal upper flange 203 and asecond or lower end 210 b proximal lower flange 202. In this embodiment,insulating sleeve 210 is a tubular having a cylindrical cross-section ina plane perpendicular to axis 215, however, in general, the insulatingsleeve (e.g., sleeve 210) may have any suitable cross-sectional shape(e.g., square, rectangular, triangular, oval, etc.).

As best shown in FIGS. 3 and 4, sleeve 210 is axially positioned betweenflanges 202, 203 and is coaxially disposed about assembly 230. Sleeve210 has an inner radius R₂₁₀ that is greater than the outer radius R₂₃₀of separator assembly 230 (FIG. 4). Thus, sleeve 210 is radially spacedfrom assembly 230, thereby defining an insulating annulus or chamber 216extending radially between sleeve 210 and assembly 230 and extendingaxially between ends 210 a, 210 b. In addition, sleeve 210 includes apair of circumferentially spaced openings 213 disposed at the same axialposition proximal upper end 210 a. In this embodiment, openings 213 areuniformly spaced about 180° apart about axis 215. Each opening 213extends radially through sleeve 210 to insulating chamber 216, and thus,each opening 213 is in fluid communication with insulating chamber 216.As will be described in more detail below, during operation of fluidseparator 200, fluid flows through openings 213 and into insulatingchamber 216. Consequently, each opening 213 may also be referred toherein as an inlet 213 of annulus 216.

An annular seal 211 is disposed within annulus 216 proximal upper end210 a and axially above inlets 213. Seal 211 extends radially betweeninsulating sleeve 210 and separator assembly 230, and sealingly engagesthe cylindrical inner surface of insulating sleeve 210 and the outercylindrical surface of separator assembly 230. Seal 211 restricts and/orprevents fluid within annulus 216 from flowing axially upward to theinterface between upper end 210 a and upper flange 203.

As best shown in FIGS. 3 and 5, lower end 210 b of sleeve 210 does notextend axially to or engage lower flange 202. Rather, lower end 210 b ofsleeve 210 is axially spaced apart from flange 202, thereby defining anannular gap 214. An upper or first annular gasket 217 a and a second orlower annular gasket 217 b are disposed in insulating chamber 216proximal lower end 210 b and axially above gap 214. Lower gasket 217 bis axially spaced below upper gasket 217 a, and each annular gasket 217a, b extends radially between insulating sleeve 210 and separatorassembly 230. As best shown in FIGS. 5, 14, and 15, the radially outercylindrical surface of upper gasket 217 a sealingly engages the radiallyinner cylindrical surface of sleeve 210, and the radially innercylindrical surface of lower gasket 217 b sealingly engages the radiallyouter cylindrical surface of separator assembly 230. However, theradially inner surface of upper gasket 217 a includes a plurality ofcircumferentially spaced recesses 218 a, each recess 218 a extendingaxially through gasket 217 a from the upper surface of gasket 217 a tothe lower surface of gasket 217 a. Further, the radially outer surfaceof lower gasket 217 b includes a plurality of circumferentially spacedrecesses 218 b, each recess 218 b extend axially through gasket 217 bfrom the upper surface of gasket 217 a to the lower surface of gasket217 b. Recesses 218 a, b define axial flow passages 219 a, b,respectively, in gaskets 217 a, b, respectively. Flow passages 219 a, bare in fluid communication with insulating chamber 216 and annular gap214. Thus, gap 214 is in fluid communication with insulating chamber 216via flow passages 219 a, b. As will be described in more detail below,during operation of fluid separator 200, fluid flows from insulatingchamber 216, through flow passages, 219 a, b and radially outwardthrough gap 214. Consequently, annular gap 214 may also be referred toherein as an outlet 214 of annulus 216. Gasket 217 a is preferablyoriented such that recesses 218 a are angularly offset from recesses 218b in order to create a more tortuous path for fluid flowing frominsulating chamber 216 to outlet 214 and a slight backpressure withininsulating chamber 216.

In general, seal 211 and gaskets 217 a, b may comprise any suitablematerial(s) capable of sealingly engaging insulating sleeve 210 and/orseparator assembly 230. However, seal 211 and gaskets 217 a, bpreferably comprises a resilient and durable material such as neopreneor rubber. In this embodiment, seal 211 and each gasket 217 a, b is aneoprene gasket.

Referring again to FIGS. 2 and 3, each inlet 213 is in fluidcommunication with a cooling device 220 that pumps a cooling medium orfluid 221, typically cold air, through each inlet 213 and intoinsulating chamber 216. In general, each cooling device 310 may compriseany suitable device capable of cooling a fluid and pumping the coolingfluid 221 through insulating chamber 216 including, without limitation,a thermoelectric cooling device. Examples of a suitable devices for thecooling device (e.g., cooling device 310) include a 2,800 BTU VortexCooler™ available from ITW Air Management Co. of Cincinnati, Ohio, andVortex Koolers available from Rittal Corporation of Urbana, Ohio.

As will be described in more detail below, during operation of fluidseparator 200, cooling devices 220 pump cooling fluid 221 through inlets213 into insulating chamber 216. The cooling fluid 221 flows axiallydownward through insulating chamber 216 and flow passages 219 a, b, andthen flows radially outward through outlet 214, thereby exiting fluidseparator 200. In this embodiment, upon exiting outlet 214, the coolingfluid 221 is exhausted to the atmosphere. However, in other embodiments,the cooling fluid (e.g., cooling fluid 221) may be returned to thecooling devices (e.g., cooling devices 220), re-cooled, and thenrecirculated back through the insulating chamber (e.g., insulatingchamber 216). Depending on the desired temperature of the cooling fluid221, one or both cooling devices 220 may be operated. For example,during the summer, operation of both cooling devices 221 may benecessary to achieve the desired temperature for the cooling fluid 221flowing through insulating chamber 216. However, during the winter,operation of only one cooling device 220 may be necessary to achieve thedesired temperature for the cooling fluid 221 flowing through insulatingchamber 216.

As best shown in FIG. 1, sleeve 210 also includes a plurality of axiallyspaced sensor ports 222, each port 222 extending radially through sleeve210 from the radially outer surface of sleeve 210 to the radially innersurface of sleeve 210 and insulating chamber 216. A temperature sensor314 is positioned in each sensor port 222. In general, temperaturesensors 314 measure the temperature of the cooling fluid 221 at variouspoints along its flow path through fluid separator 200. The axiallylowermost port 222 is positioned adjacent outlet 214, and thus,temperature sensor 314 in the axially lowermost port 222 measures thetemperature of cooling fluid 221 at outlet 214. Accordingly, temperaturesensor 314 in the axially lowermost port 222 may be referred to as thecooling fluid outlet temperature sensor 314. Moreover, one temperaturesensor 314 is positioned at each inlet 213 to measure the temperature ofcooling fluid 221 at each inlet 213. The temperature sensors 314positioned at inlets 213 may be referred to as the cooling fluid inlettemperature sensors 314.

In general, sleeve 210 may comprise any suitable material(s) including,without limitation, metals and metal alloys (e.g., aluminum, steel,etc.), non-metal(s) (e.g., ceramic, polymer, etc.), composite (e.g.,carbon fiber and epoxy composite), or combinations thereof. However,sleeve 210 preferably comprise a durable material suitable for use inchemical and hydrocarbon processing environments. In this embodiment,sleeve 210 comprises two layers, a radially inner layer comprisingfiberglass pre-formed insulation and a radially outer protective layercomprising carbon fiber reinforced polymer (e.g., epoxy, polyester,vinyl ester, or nylon). The radially inner layer limits heat transferradially across sleeve 210, while the radially outer layer provides arelatively hard shell that protects the radially inner insulation duringmaintenance and collateral activities.

Referring again to FIGS. 3-6, separator assembly 230 has a central orlongitudinal axis 235 and extends between a first or lower end 230 a atlower flange 202 and a second or upper end 230 b at upper flange 203. Aswill be described in more detail below, lower end 230 a defines an inlet231 for unconditioned sample fluid 101 and an outlet 232 forcontaminants 102, and upper end 230 b defines an outlet 233 forconditioned sample fluid 103. In other words, lower end 230 a functionsas both inlet 231 and outlet 232, whereas upper end 230 b functionssolely as outlet 233.

Separator assembly 230 includes a radially outer tubular fluid conduit234, a radially inner support rod 240 coaxially disposed within conduit234, a plurality of plates 250, a plurality of baffles 260, a pluralityof separating members 270, and a plurality of spacers 290. In thisembodiment, separator assembly 230 includes two plates 250—one upperplate 250 (FIG. 4) axially positioned at upper end 230 b and one lowerplate 250 (FIG. 5) axially positioned at lower end 230 a. As best shownin FIGS. 3 and 4, baffles 260 are axially positioned proximal upper end230 b, and separating members 270 are axially positioned between baffles260 and lower plate 250. Each plate 250, baffle 260, and separatormember 270 extends radially between support rod 240 and conduit 234.Further, one spacer 290 is axially positioned between each pair ofaxially adjacent baffles 260 and each pair of axially adjacentseparating members 270. Each spacer 290 comprises a washer or donuthaving a central throughbore that slidingly receives support rod 240. Toachieve the desired axial spacing of baffles 260 and separating members270, each spacer 290 preferably has an axial height ranging from 1/32in. to ¼ in.

Referring still to FIGS. 3-6, conduit 234 has a central axis coincidentwith axes 205, 215, 235 and extends axially between ends 230 a, b andflanges 202, 203. In this embodiment, conduit 234 is integral withflange 202, 203 at each end 230 a, b, respectively. For example, flanges202, 203 may be molded or cast as part of conduit 234, machined from thesame material as conduit 234, or manufacture separate from conduit 234and then welded to the ends of conduit 234. Conduit 234 is an elongatecylindrical tubular or pipe that prevents fluid communication betweenthe fluids flowing within separator assembly 230 (e.g., unconditionedsample fluid 101, contaminants 102, and conditioned sample fluid 103)and the cooling fluid 221 flowing through insulating chamber 216.

Support rod 240 is an elongate generally cylindrical rod coaxiallydisposed within conduit 234, and thus, similar to conduit 234, supportrod 240 has a central axis coincident with axes 205, 215, 235. Inaddition, support rod 240 extends axially between a first or lower end240 a at end 230 a and a second or upper end 240 b at end 230 b. As willbe described in more detail below, rod 240 extends through a centralthroughbore in each plate 250, baffle 260, separator member 270, andspacer 290, thereby radially aligning plates 250, baffles 260,separating members 270, and spacers 290. As best shown in FIG. 6,support rod 240 has an outer radius R₂₄₀ that is preferably between 1/16in. and 3/16 in. In this embodiment, radius R₂₄₀ is ⅛ in.

Rod 240 comprises external threads at both ends 240 a, b, which engagemating nuts 241. In general, nuts 241 maintain the axial position ofplates 250, baffles 260, separating members 270, and spacers 290relative to support rod 240. In other words, nuts 241 restrict axialmovement of plates 250, baffles 260, separating members 270, and spacers290 relative to support rod 240. Specifically, as best shown in FIG. 5,one nut 241 threaded onto lower end 240 a of support rod 230 axiallyabuts and engages lower plate 250. Nut 241 at lower end 240 a restrictsand/or prevents lower plate 250, separating members 270, and spacers 290axially positioned between adjacent separating members 270 from slidingoff support rod 240. Still further, as best shown in FIG. 4, four nuts241 are provided proximal upper end 240 b to maintain the axial positionof baffles 260 and upper plate 250 relative to rod 240—one pair of nuts241 are axially positioned immediately above and below upper plate 250,thereby maintaining the axial position of upper plate 250, and the otherpair of nuts 241 are axially positioned immediately above and below thegroup of three baffles 260, thereby defining and limiting the axialposition of baffles 260. For convenience purposes, nuts 241 may also bereferred to as first, second, third, fourth, and fifth nuts 241 based ontheir axial position along rod 240 moving from lower end 240 a to upperend 240 b (i.e., the lower-most nut 241 is the first nut 241, the nextnut 241 axially above the first nut 241 is the second nut 241, and soon).

Referring now to FIGS. 3-5, 7 and 8, each plate 250 is a cylindricaldisc having a planar upper surface 251, a planar lower surface 252parallel to upper surface 251, and a cylindrical radially outer surface253 extending axially between surfaces 251, 252. In addition, each plate250 has an axial thickness T₂₅₀ measured axially between surfaces 251,252, and an outer radius R₂₅₀ measured radially from axes 205, 215, 235to the outer surface 253.

Referring specifically to FIGS. 7 and 8, outer radius R₂₅₀ is preferablysubstantially the same or slightly less than the inner radius of conduit234 such that outer surface 253 slidingly engages conduit 234 when plate250 is coaxially disposed within conduit 234, and axial thickness T₂₅₀preferably ranges from about 1/16 in. to about ¼ in. In this embodiment,outer radius R₂₅₀, and hence the inner radius of conduit 234, is 1¼ in.and axial thickness T₂₅₀ is ⅛ in.

As best shown in FIGS. 7 and 8, each plate 250 includes a centralthroughbore 254 and a plurality of throughbores 255 radially positionedbetween central throughbore 254 and radially outer surface 253. Eachbore 254, 255 extends axially through plate 250 from upper surface 251to lower surface 252. In this embodiment, a first set of eight bores 255are disposed at the same radial position and arranged in a first annularrow 255 a, and a second set of fourteen bores 255 are disposed at thesame radial position and arranged in a second annular row 255 b. Row 255a is radially positioned between central bore 254 and annular row 255 b.

Referring still to FIGS. 7 and 8, central bore 254 has a radius R₂₅₄ andeach bore 255 has a radius R₂₅₅. In this embodiment, each bore 255 hasthe same radius R₂₅₅. As best shown in FIGS. 4 and 5, central bore 254slidingly receives rod 240, and thus, radius R₂₅₄ is preferablysubstantially the same or slightly less than the outer radius of rod240. As previously described, support rod 240 has an outer radius R₂₄₀that is preferably between 1/16 in. and 3/16 in., and thus, radius R₂₅₄is preferably between 1/16 in. and 3/16 in. In this embodiment, radiusR₂₄₀ is ⅛ in, and thus, radius R₂₅₄ is about ⅛ in. or slightly less than⅛ in. Still further, radius R₂₅₅ of each bore 255 preferably ranges fromabout 1/16 in. to 3/16 in. In this embodiment, the radius R₂₅₅ of eachbore 255 is ⅛ in.

As will be described in more detail below, throughbores 255 allow fluidwithin separator assembly 230 to flow axially through each plate 250. Inparticular, throughbores 255 in lower plate 250 allow unconditionedsample fluid 101, typically in a gaseous phase with some suspendedparticulate matter, to flow through inlet 231 into separator assembly230 and allow contaminants 102, typically in a liquid phase, to flowaxially downward through outlet 232 and out of separator assembly 230.Further, throughbores 255 in upper plate 250 allow conditioned samplefluid 103, typically in a gaseous phase, to flow through outlet 233 andout of separator assembly 230. Consequently, throughbores 255 in plates250 may also be referred to as fluid ports or fluid orifices.

Referring again to FIGS. 3 and 4, in this embodiment, separator assembly230 includes three baffles 260 axially positioned proximal upper end 230b between separating members 270 and upper plate 250. Baffles 260axially spaced apart and are arranged one-above-the-other in a verticalor axial stack. For convenience purposes, the three baffles 260 may bereferred to as the first, second, and third baffles 260 based on theirorder moving axially along rod 240 from lower end 240 a to upper end 240b (i.e., the lower-most baffle 260 is the first baffle 260 and theupper-most baffle 260 is the third baffle 260).

As previously described, one nut 241 is axially positioned immediatelybelow the lowermost or first baffle 260 and one nut 241 is positionedimmediately above the upper most or third baffle 260, thereby limitingthe axial movement and positions of baffles 260. In addition, one spacer290 is axially positioned between each pair of adjacent baffles 260;spacers 290 maintain axial separation of baffles 260. In other words,axially adjacent baffles 260 do not touch or engage each other.

Referring now to FIGS. 3, 4, 9 and 10, each baffle 260 is a generallydome-shaped disc having a convex surface 261 and a concave surface 262parallel to surface 261. In this embodiment, surfaces 261, 262 arespherical surfaces. Each baffle 260 also includes an annular lip orflange 263 along its entire outer periphery. Lip 263 defines a radiallyoutermost cylindrical surface 264 on each baffle 260. As best shown inFIGS. 3 and 4, in this embodiment, first and second baffles 260 are eachoriented with concave surface 262 facing downward, whereas third baffle260 is oriented with concave surface 262 facing upwards and toward upperplate 250. Further, although first and second baffles 260 are axiallyspaced apart and do not directly engage each other, first and secondbaffles 260 are arranged in a nested configuration wherein first baffle260 extends partially into the concave recess defined by concave surface262 of second baffle 260.

Referring specifically to FIGS. 9 and 10, each baffle 260 has an axialthickness T₂₆₀ measured axially between surfaces 261, 262, and an outerradius R₂₆₀ measured radially from axes 205, 215, 235 to the outersurface 264. Outer radius R₂₆₀ is preferably substantially the same orslightly less than the inner radius of conduit 234 such that outersurface 264 slidingly engages conduit 234 when baffle 260 is coaxiallydisposed within conduit 234, and axial thickness T₂₆₀ preferably rangesfrom about 1/16 in. to about ¼ in. In this embodiment, outer radiusR₂₆₀, and hence the inner radius of conduit 234, is 1¼ in. and axialthickness T₂₆₀ is ⅛ in.

Referring still to FIGS. 9 and 10, each baffle 260 includes a centralthroughbore 265. As best shown in FIGS. 3 and 4, central throughbore 265of each baffle 260 slidingly receives rod 240. Thus, baffles 260 arecoaxially disposed about rod 240 and coaxially disposed within conduit234. In addition, each baffle 260 includes a plurality of throughbores266 radially positioned between central throughbore 265 and annularflange 263. In this embodiment, four throughbores 266 are provided.However, in general, any suitable number of throughbores 266 may beprovided. Each throughbore 266 is disposed at a radius R₂₆₆. In thisembodiment, the radius R₂₆₆ of each throughbore 266 is the same.Throughbores 266 are preferably positioned in the radially outer 50% ofbaffle 260, and more preferably positioned in the radially outer 25% ofbaffle 260. In other words, radius R₂₆₆ of each throughbore 266 ispreferably greater than 50% of outer radius R₂₆₀, and more preferablygreater than 75% of outer radius R₂₆₀.

As previously described, in this embodiment, each baffle 260 includesfour throughbores 266. In particular, throughbores 266 are uniformlyangularly spaced about 90° apart. However, in other embodiments, thethroughbores in the baffles (e.g., throughbores 266 in baffles 260) maybe non-uniformly angularly spaced.

Baffles 260 are preferably coupled to rod 240 and angularly orientedrelative to each other such that throughbores 266 on axially adjacentbaffles 260 are disposed at different angular position relative to axes205, 215, 235. For example, baffles 260 may be positioned on rod 240without regard to the angular orientation of throughbores 266, in whichcase, throughbores 266 will most likely be positioned at random anddifferent angular positions on adjacent baffles 260. As a result, theunconditioned sample fluid 101 flowing axially upward through separatorassembly 230 is forced to change direction, and thus, take a moretortuous path to flow from bores 266 of one baffle 260 in route to bores266 of the next axially adjacent baffle 260.

Referring still to FIGS. 9 and 10, central bore 265 has a radiusR_(265′) and each bore 266 has a radius R_(266′). In this embodiment,each bore 266 has the same radius R_(266′). As best shown in FIG. 4,central bore 265 slidingly receives rod 240, and thus, radius R_(265′)is preferably substantially the same or slightly less than the outerradius of rod 240. As previously described, support rod 240 has an outerradius R₂₄₀ that is preferably between 1/16 in. and 3/16 in., and thus,radius R_(265′) is preferably between 1/16 in. and 3/16 in. In thisembodiment, radius R₂₄₀ is ⅛ in, and thus, radius R_(265′) is about ⅛in. or slightly less than ⅛ in. Still further, radius R_(266′) of eachbore 266 preferably ranges from 1/64 in. to ⅛ in. In this embodiment,the radius R_(266′) of each bore 266 is 1/16 in.

As will be described in more detail below, throughbores 266 allow fluidwithin separator assembly 230 to flow axially through each baffle 260.In particular, throughbores 266 in baffles 260 allow unconditionedsample fluid 101 (or partially conditioned fluid sample), typically in agaseous phase, to flow axially upward through each baffle 260 towardsoutlet 233 of separator assembly 230. Accordingly, throughbores 266 mayalso be referred to as gas orifices or ports. Further, the gaps and/orannulus radially positioned between radially outer surface 264 of eachbaffle 260 and conduit 234 allow contaminants 102, typically in a liquidphase, to drip and flow axially downward through each baffle 260 towardoutlet 233. Accordingly, the gaps and/or annuli positioned radiallybetween each baffle 260 and conduit 234 may be referred to as draingaps.

Referring now to FIGS. 3 and 6, in this embodiment, separator assembly230 includes a plurality of separating members 270 generally arrangedone-above-the-other in a vertical or axial stack. The lowermostseparator member 270 axially abuts and engages lower plate 250. Inaddition, one spacer 290 is axially positioned between each pair ofadjacent separating members 270. Thus, nut 241 disposed immediatelybelow lower plate 250 supports lower plate 250 as well as the pluralityof separating members 270 and spacers 290 disposed between separatingmembers 270. Spacers 290 maintain axial separation of separating members270. In other words, axially separating members 270 do not touch orengage each other. The axial spacing between adjacent separating members270 preferably ranges from 1/32 in. to ¼ in. Spacers 290 are preferablysized to maintain the preferred axial separation of adjacent separatingmembers 270.

Referring now to FIGS. 6, 11 and 12, each separator member 270 isgenerally an inverted cone extending between an upper end 270 a and alower end 270 b. In addition, each separator member 270 has afrustoconical inner surface 271 and a frustoconical outer surface 272parallel to inner surface 271. Upper end 270 a includes an annular lipor flange 273 that extends along the entire outer periphery of upper end270 a. Lip 273 defines a radially outermost cylindrical surface 274 oneach separator member 270. In this embodiment, lower end 270 b isgenerally flat, however, in other embodiments, the lower end of eachseparating member (e.g., lower end 270 b of each separator member 270)may be rounded, pointed, etc. Frustoconical inner surface 271 defines aninner cone-shaped cavity or recess 278 extending axially downward fromthe open upper end 270 a. As best shown in FIGS. 3 and 6, with theexception of the lowermost separator member 270 that engages lower plate250, each separator member 270 extends into recess 278 of the separatormember 270 axially positioned immediately below it. Thus, separatormembers 270 may be described as being arranged in a nested configurationwherein each separator member 270 extends axially into recess 278 of anaxially adjacent separator member 270.

Referring specifically to FIGS. 11 and 12, each separator member 270 hasan axial thickness T₂₇₀ measured perpendicularly to surfaces 271, 272and an outer radius R₂₇₀ measured radially from axes 205, 215, 235 toouter surface 274. Outer radius R₂₇₀ is preferably substantially thesame or slightly less than the inner radius of conduit 234 such thatouter surface 274 slidingly engages conduit 234 when separating members270 are coaxially disposed within conduit 234, and axial thickness T₂₇₀preferably ranges from about 1/16 in. to about ¼ in. In this embodiment,outer radius R₂₇₀, and hence the inner radius of conduit 234, is 1¼ in.and axial thickness T₂₇₀ is ⅛ in.

Each separator member 270 also includes a central throughbore 275 atlower end 270 b. As best shown in FIGS. 3 and 6, central throughbore 275of each separator member 270 slidingly receives rod 240. Thus, separatormembers 270 are coaxially disposed about rod 240 and coaxially disposedwithin conduit 234. In addition, each separator member 270 includes atleast one throughbore 276 proximal upper end 270 a, and at least onethroughbore 277 proximal lower end 270 b. In general, each separatormember 270 may include any suitable number of throughbores 276 and anysuitable number of throughbores 277. Further, different separatormembers 270 in separator assembly 230 may have different numbers ofthroughbores 276 and/or throughbores 277. However, the number ofthroughbores 276 in each separator member 270 preferably ranges from oneto four, and the number of throughbores 277 in each separator member 270also preferably ranges from one to four. In the embodiment of separatormember 270 shown in FIGS. 11 and 12, four throughbores 276 and fourthroughbores 277 are provided.

As will be described in more detail below, throughbores 276, 277 allowfluid within separator assembly 230 to flow axially through eachseparator member 270. In particular, throughbores 276 in separatingmembers 270 allow unconditioned sample fluid 101 (or partiallyconditioned fluid sample), typically in a gaseous phase with someparticulate matter, to flow axially upward through each separator member270 towards outlet 233 of separator assembly 230. Accordingly,throughbores 276 may also be referred to as gas orifices or ports.Further, throughbores 277 in separating members 270 allow contaminants102, typically in a liquid phase, to drip and flow axially downwardthrough each separator member 270 towards outlet 233. Accordingly,throughbores 277 may also be referred to as drain orifices or ports.

Referring still to FIGS. 11 and 12, each throughbore 276 is disposed ata radius R₂₇₆ and each throughbore 277 is disposed at a radius R₂₇₇ thatis less than radius R₂₇₆. In this embodiment, the radius R₂₇₆ of eachthroughbore 276 is the same and the radius R₂₇₇ of each throughbore 277is the same. Since each separator member 270 has an inverted conegeometry, throughbores 276 proximal upper end 270 a are radiallypositioned in the radially outer portion of each separator member 270,and throughbores 277 proximal lower end 270 b are radially positioned inthe radially inner portion of each separator member 270.

In this embodiment of separator member 270, the four throughbores 276are uniformly circumferentially spaced about 90° apart, and the fourthroughbores 277 are uniformly circumferentially spaced about 90° apart.However, in general, the throughbores in one or more separating members(e.g., throughbores 276, 277 in separating members 270) may benon-uniformly circumferentially spaced.

Separating members 270 are preferably coupled to rod 240 and angularlyoriented relative to each other such that throughbores 276 on axiallyadjacent separating members 270 are disposed at different angularposition relative to axes 205, 215, 235. In other words, throughbores276 of axially adjacent separating members 270 are preferably angularlyoffset or staggered. As a result, fluid (e.g., unconditioned samplefluid 101) flowing axially upward through separator assembly 230 isforced to change direction, and thus, take a more tortuous path whenflowing from the bores 276 of one separator member 270 in route to thebores 276 of the next axially adjacent separator member 270.

Referring still to FIGS. 11 and 12, central bore 275 has a radiusR_(275′), each bore 276 has a radius R_(276′), and each bore 277 has aradius R_(277′) that is greater than radius R_(276′). In thisembodiment, the radius R_(276′) of each bore 276 is the same, and theradius R_(277′) of each bore 277 is the same. As best shown in FIG. 4,central bore 275 slidingly receives rod 240, and thus, radius R_(275′)is preferably substantially the same or slightly less than the outerradius of rod 240. As previously described, support rod 240 has an outerradius R₂₄₀ that is preferably between 1/16 in. and 3/16 in., and thus,radius R_(275′) is preferably between 1/16 in. and 3/16 in. In thisembodiment, radius R₂₄₀ is ⅛ in, and thus, radius R_(275′) is about ⅛in. or slightly less than ⅛ in. Radius R_(276′) of each bore 276preferably ranges from 1/64 in. to 1/16 in., and radius R_(277′) of eachbore 277 preferably ranges from 1/16 in. to 3/16 in. As will bedescribed in more detail below, radius R_(276′) and radius R_(277′) ofgas orifices 276 and drain ports 277, respectively, may vary acrossdifferent separator members 270 within separator assembly 230.

In general, the components of separator assembly 230 (e.g., conduit 234,plates 250, baffles 260, separating members 270, spacers 290, rod 240,etc.) may comprise any suitable materials such as metal(s) and metalalloys (e.g., aluminum, steel, etc.), non-metals (e.g., ceramics,polymers, etc.), composites, or combinations thereof. However, thecomponents of separator assembly 230 preferably comprise rigid, durablematerials that are capable of withstanding extended period of exposureto the relatively conditions (e.g., temperatures, corrosive effects,etc.) imposed by cooling fluid 221 and unconditioned sample fluid 101.Thus, in the embodiments described herein, the components of separatorassembly 230 are made from stainless steel.

Referring briefly to FIG. 7, in this embodiment of separator assembly230, different sets or groups of separating members 270 have differentnumbers of gas orifices 276, different numbers of drain ports 277,differently sized gas orifices 276, and differently sized drain ports277 based on their relative axial positions within assembly 230. Inparticular, the plurality of separator members 270 in separator assembly230 may be divided into different sets or groups 270-1, 270-2, 270-3,270-4. In the embodiment of separator assembly 230 shown in FIG. 7,there are one-hundred total separator members 270, which are dividedinto four groups 270-1, 270-2, 270-3, 270-4 of twenty-five separatormembers 270. Groups 270-1, 270-2, 270-3, 270-4 are positioned one abovethe other starting at lower end 230 a. Thus, group 270-1 is thelowermost set of twenty-five separator members 270, group 270-4 is theupper-most set of twenty-five separators 270, group 270-2 is positionedaxially adjacent group 270-1, and group 270-3 is axially positionedbetween groups 270-2, 270-4.

Within a given group 270-1, 270-2, 270-3, 270-4, separator members 270are identical. Thus, within a given group 270-1, 270-2, 270-3, 270-4,each separator 270 has the same number of gas orifices 276 and the samenumber of drain ports 277. Further, within a given group 270-1, 270-2,270-3, 270-4, each gas orifice 276 has the same radius R_(276′) and eachdrain port 277 has the same radius R_(277′). However, separator members270 in different groups 270-1, 270-2, 270-3, 270-4 are different. Inparticular, separator members 270 in different groups 270-1, 270-2,270-3, 270-4 have different numbers of gas orifices 276 and differentnumbers of drain ports 277. For example, in the embodiment shown in FIG.7, the number of gas orifices 276 and drain ports 277 generallydecreases moving axially upward from group-to-group. Specifically, ingroup 270-1, each separator member 270 has four gas orifices 276 andfour drain ports 277; in group 270-2, each separator member 270 hasthree gas orifices 276 and three drain ports 277; in group 270-3, eachseparator member 270 has two gas orifices 276 and two drain ports 277;and in group 270-4, each separator member 270 has one gas orifice 276and two drain ports 277.

In this embodiment, gas orifices 276 of separators 270 in differentgroups 270-1, 270-2, 270-3, 270-4 have the same radii R_(276′), anddrain ports 277 of separators 270 in different groups 270-1, 270-2,270-3, 270-4 have the same radii R_(277′). In particular, in each group270-1, 270-2, 270-3, 270-4, radius R_(276′) of each gas orifice 276 is1/16 in. and radius R_(277′) of each drain port 277 is 1/16 in. However,in other embodiments, gas orifices 276 of separators 270 in differentgroups 270-1, 270-2, 270-3, 270-4 may have different radii R_(276′),and/or drain ports 277 of separators 270 in different groups 270-1,270-2, 270-3, 270-4 may have different radii R_(277′). For example, theradius R_(276′) of gas orifices 276 of separators 270 in differentgroups 270-1, 270-2, 270-3, 270-4 may decrease from group-to-groupmoving axially upward, and radius R_(277′) of drain ports 277 ofseparators 270 in different groups 270-1, 270-2, 270-3, 270-4 maydecrease from group-to-group moving axially upward.

Referring now to FIGS. 3-7, to assembly separator assembly 230, firstnut 241 is threaded onto lower end 240 a of support rod 240, and thenplates 250, separating members 270, spacers 290, baffles 260, andremaining second, third, fourth, and fifth nuts 241 are coupled to rod240 in order from the bottom up, one after the other. Plates 250,separating members 270, spacers 290, and baffles 260 slidingly engagerod 240, and thus, an axial force can be applied to these components toaxially urge them along rod 240 from upper end 240 b to lower end 240 a.Alternatively, rod 240 may be positioned in a vertical orientation suchthat the weight of plates 250, separating members 270, spacers 290, andbaffles 260 naturally urges them axially downward along rod 240 towardlower end 240 a.

Once first nut 241 is threaded onto lower end 240 a, upper end 240 b ofsupport rod 240 is axially inserted into central throughbore 254 oflower plate 250, and rod 240 is axially advanced through throughbore 254until lower plate 250 axially abuts first nut 241 at lower end 240 a.Next, upper end 240 b of support rod 240 is axially inserted intocentral throughbore 275 of lower-most separator member 270, and rod 240is axially advanced through throughbore 275 until lower end 270 baxially abuts lower plate 250. Then, rod 240 is axially advanced throughspacers 290 and central throughbore 275 of the remaining separatingmembers 270 in an alternating fashion until all the separating members270 are coupled to rod 240. As previously described, gas orifices 276 inaxially adjacent separating members 270 are preferably positioned atdifferent angular orientations. Neither rod 240 nor central throughbores275 of separating members 270 are keyed, and thus, separating members270 are free to rotate about axis 235 during assembly. As a result,during assembly, the angular orientation of gas orifices 276 of oneseparator member 270 relative to the angular orientation of the gasorifices 276 of every other separator member 270 is random.Consequently, the probability of two or more axially adjacent separatingmembers 270 having gas orifices 276 with the same angular orientation isrelatively low, and the probability of every separator member 270 havinggas orifices 276 with the same angular orientation is extremely low.

As previously described, in the embodiment shown in FIGS. 3 and 7, theplurality of separating members 270 are arranged into groups 270-1,270-2, 270-3, 270-4, where the number and radius R_(276′) of gasorifices 276 of each separating member 270 in the same, but the numberand radius R_(276′) of gas orifices 276 of separating members 270 indifferent groups are different. During assembly of separator assembly230, special attention should be given to the order in which theseparator members 270 are advanced onto rod 240 to achieve the desiredarrangement of groups 270-1, 270-2, 270-3, 270-4. Specifically,separator members 270 designed and configured for use in group 270-1should be placed on rod 240, before separator members 270 designed andconfigured for use in group 270-2; separator members 270 designed andconfigured for use in group 270-2 should be placed on rod 240, beforeseparator members 270 designed and configured for use in group 270-3;and separator members 270 designed and configured for use in group 270-3should be placed on rod 240, before separator members 270 designed andconfigured for use in group 270-4.

Referring still to FIGS. 3-7, and moving on with the remainder of theassembly process, after the final and upper-most separator member 270 ispositioned on rod 240, second nut 241 is threaded onto upper end 240 b,followed by axial insertion of upper end 240 b into central throughbore265 of first baffle 260, which is preferably oriented with concavesurface 262 facing downward. Second nut 241 and first baffle 260 areaxially advanced along rod 240 until second baffle 260 is positionedproximal, but axially spaced from, the upper-most separator member 270,and concave surface 262 axially abuts second nut 241. Accordingly,second nut 241 maintains the axial separation of first baffle 260 andthe upper-most separator member 270. Next, two spacers 290, secondbaffle 260, and third baffle 260 are axially advanced onto rod 240 in analternating fashion; second baffle 260 is preferably oriented withconcave surface 262 facing downward similar to first baffle 260, andthird baffle 260 is preferably oriented with concave surface 262 facingupward. Then, third nut 241 is threaded onto upper end 240 b andadvanced along rod 240 until it axially abuts third baffle 260. Secondnut 241 and third nut 241 axially compress or squeeze baffles 260 andspacers 290 between baffles 260 together, thereby maintaining the axialposition of baffles 260 and spacers 290 therebetween. Lastly, fourth nut241 is threaded onto upper end 240 b, upper end 240 b is axiallyinserted and advanced through central throughbore 254 of upper plate250, and fifth nut 241 is threaded onto upper end 240 b. Fourth andfifth nuts 241 are positioned such that each axially abuts upper plate250, thereby maintaining the axial position of upper plate 250.

Referring now to FIG. 3, fifth nut 241 is preferably axially positionedon rod 240 such that threaded upper end 240 b extends axially upwardfrom fifth nut 241. This threaded extension of rod 240 allows anextractor tool (not shown) having a counterbore with mating internalthreads to be threaded onto upper end 240 a to manipulate rod 240,plates 250, baffles 260, and separating members 270 coupled thereto. Forexample, once threaded to upper end 240 b, the extractor tool may beused to pull rod 240, plates 250, baffles 260, and separating members270 from conduit 234 for maintenance and/or cleaning operations, andinsert rod 240, plates 250, baffles 260, and separating members 270 intoconduit 234 following maintenance and/or cleaning operations.Accordingly, embodiments of fluid separator 200 enable removal of rod240, plates 250, baffles 260, and separating members 270 axially formaintenance and/or cleaning operations without necessitating the removalof conduit 234 or insulating sleeve 210.

Referring back to FIG. 2, sample monitoring and control system 300includes a plurality of temperature sensors, a plurality of flow controlvalves, and a plurality of valve actuators, which work together tomonitor and control the conditioning of the sampled fluid withinseparator 200. The information acquired by system 300 in the field iscommunicated to a control room, by hardwire or wirelessly, where it maybe monitored by a computer system and/or plant operations personnel. Thecontrol room may be on-site or remote from the processing operations. Inresponse to the acquired information, the computer system and/or plantoperations personnel may make various adjustments to the separationprocess via the control valves and valve actuators.

In this embodiment, system 300 includes a conditioned sample fluidtemperature sensor 311, one cooling fluid inlet temperature sensor 314for each cooling device 220 and cooling fluid inlet 213, one coolingfluid outlet temperature sensor 314 for outlet 214, and a plurality ofadditional cooling fluid temperature sensors 314 positioned in ports 222of sleeve 210 between inlets 213 and outlet 214. Conditioned samplefluid temperature sensor 311 is positioned at or proximal outlet 233 ofseparator 200, and measures the temperature of conditioned sample fluid103 at outlet 233. Each cooling fluid inlet temperature sensor 314 ispositioned at or proximal one inlet 213 of separator 200, and measuresthe temperature of the cooling fluid 221 at that particular inlet 213.Further cooling fluid outlet temperature sensor 314 is positioned at orproximal cooling fluid outlet 214, and measures the temperature ofcooling fluid 221 at outlet 214. The remaining cooling fluid temperaturesensors 314 disposed in sensor ports 222 between inlets 213 and outlet214 measure the temperature of cooling fluid 221 flowing throughinsulating chamber 216 at different axial positions along sleeve 210 andchamber 216.

Referring still to FIG. 2, in this embodiment, system 300 also includesone cooling fluid inlet control valve 321 and associated valve controlactuator 331 for each cooling device 220, and a conditioned fluid outletcontrol valve 322 and associated valve control actuator 332. Valvecontrol actuators 331, via valves 321, control the flow of cooling fluid221 into cooling devices 220 and inlets 213 of separator 200. Inparticular, valves 321 are in an opened position, cooling fluid 221flows to cooling devices 220 and inlets 213, however, when valves 321are in a closed position, cooling fluid 221 is restricted and/orprevented from flowing to cooling devices 220 and inlets 213. Valvecontrol actuators 331 actuate valves 321 between the opened position andthe closed position. Further, as each valve 321 includes its ownactuator 331, each valve 321 can be independently controlled. Eachcooling device 220 also includes a cooling device actuator 341 thatindependently controls whether the particular cooling device 220 is onor off, as well as the degree of cooling power output by each coolingdevice 220.

Valve control actuator 332, via valve 322, controls the flow ofconditioned fluid sample 103 through outlet 233 of separator 200. Inparticular, valve 322 is in an opened position, conditioned sample fluid103 flows from separator 200 to the downstream equipment (e.g.,analytical hardware), however, when valve 322 is in a closed position,conditioned sample fluid 103 is restricted and/or prevented from flowingthrough outlet 233 from separator 200 to the downstream equipment. Valvecontrol actuator 332 actuates valves 322 between the opened position andthe closed position. In general, each control actuators (e.g., actuators331, 332, 341) may be any suitable type of actuator including, withoutlimitation, electronic, hydraulic, or pneumatic actuators.

By employing the temperature sensors (e.g., temperature sensors 311,314), valves (e.g., valves 321, 322), and actuators (e.g., actuators331, 332, 341) previously described, system 300 is capable of acquiring,real-time, (a) the temperature of cooling fluid 221 at each inlet 213,at outlet 214, and at different axial positions along insulating chamber216 between inlets 213 and outlet 214; (b) the temperature ofconditioned sample fluid 103 at outlet 233; (c) the status and positionof each valve 321, 322 (e.g., open, closed, etc.); and (d) the status ofeach cooling device 220 (e.g., on, off, etc.). In addition, bycontrolling valves 321 and cooling devices 220 with actuators 331, 341,respectively, system 300 is capable of controlling the temperature ofcooling fluid 221 at inlets 213, which in turn allows system 300 tocontrol the temperature of cooling fluid 221 within insulating chamber216 and at outlet 214, as well as control the temperature of samplefluids 101, 103. Still further, by controlling valve 322 with actuator332, system 300 is capable of controlling the flow of conditioned samplefluid 103 flowing from separator 200 to the downstream equipment.

As shown in FIG. 2, in this embodiment, valves 321, 322, associatedactuators 331, 332, and condition sample fluid outlet temperature sensor311 are disposed in a housing 360 coupled to upper end 200 b ofseparator 200. Further, the cabling for temperature sensors 314 andactuators 341 is routed to housing 360. The information acquired withsystem 300 (i.e., the temperature of cooling fluid 221 at inlets 213, atoutlet 214, and within insulating chamber 216; the status and positionof valves 321, 322; the status and cooling power of cooling devices 220;and the temperature of conditioned sample fluid 103), is communicatedfrom housing 360 to the control room, and condition sample fluid 103 iscommunicated from housing 360 to the downstream equipment.

Referring now to FIGS. 2-6, during sampling operations, one or morecooling devices 220 are turned on with actuator(s) 341, and valve 321for each operating cooling device 220 is maintained in the openedposition with actuator(s) 331. As a result, cooling fluid 221 flowsthrough valve(s) 321 to cooling device(s) 220, where the temperature ofcooling fluid 221 is reduced. The temperature of cooling fluid 221 atinlet(s) 213 is preferably between 38 and 42° F. Inlet temperaturesensors 314 measure the temperature of cooling fluid 221 at inlets 213,and based on the temperature of cooling fluid 221 at inlets 213,additional cooling devices 220 may be turned on, an operating coolingdevice 220 maybe turned off, and/or the degree of cooling providedcooling devices 220 may be increased or decreased to achieve the desiredtemperature for cooling fluid 221 at inlets 213. Cooling fluid 221 iscooled by cooling devices 220 and pumped through inlets 213 intoinsulating chamber 216, and axially downward through insulating chamber216 to outlet 214, where cooling fluid 221 exits separator 200. Ascooling fluid 221 flows through insulating chamber 216, it comes intocontact with conduit 234. Simultaneously, unconditioned decoke fluidsample 101 is pulled from a bulk decoke fluid stream. The bulk decokefluid stream, and hence the unconditioned decoke fluid sample 101,typically has a temperature between 350 and 700° F. and is in a gaseousstate with some suspended particulate matter. The unconditioned decokefluid sample 101 enters inlet 101 at the lower end 230 a of separatorassembly 230 and flows through separator assembly 230. Thus, conduit 234is in contact with both the relatively cold cooling fluid 221 and therelatively hot decoke fluid stream 101. As a result, heat transferoccurs across conduit 234. In particular, thermal energy in decoke fluidstream 101 is transferred across conduit 234 and into cooling fluid 221,thereby increasing the temperature of cooling fluid 221 as it movesaxially downward through insulating chamber 216, and decreasing thetemperature of decoke fluid stream 101 as it moves axially upwardthrough separator assembly 230. In other words, the temperature ofcooling fluid 221 is coldest at inlets 213, steadily increase movingaxially downward through insulating chamber 216 toward outlet 214, andis warmest at outlet 214; and the temperature of decoke sample fluid 101is greatest at inlet 231, decreases steadily moving axially upwardthrough separator assembly 230, and is coolest at outlet 233. In thissense, separator 200 operates like a heat exchanger—moving thermalenergy from decoke fluid stream 101 into cooling fluid 221. Thetemperature of cooling fluid 221 at different axial positions betweeninlets 213 and outlet 214 is measured with the remaining temperaturesensors 314 in ports 222, and thus, the increase in temperature ofcooling fluid 221 can be monitored and tracked as it progresses frominlet 213 to outlet 214.

Referring now to FIGS. 3 and 5, the unconditioned decoke fluid sample101 enters inlet 101 at the lower end 230 a of separator assembly 230and migrates upward through separator assembly 230. Upon entry intoseparator assembly 230, unconditioned decoke fluid sample 101 firstencounters lower plate 250. Within separator 200, unconditioned decokefluid sample 101 has its maximum temperature at inlet 231. Lower plate250, being in direct and/or indirect contact with conduit 234, has atemperature that is less than unconditioned decoke fluid sample 101 atinlet 231. As unconditioned decoke fluid 101 encounters lower plate 250,it is cooled as it contacts lower plate 250 and is forced to flowthrough bores 255 in lower plate 250. Further, due to the radius R₂₅₅ ofbores 255, some of the relatively large particulate matter inunconditioned decoke sample fluid 101 is restricted and/or preventedfrom flowing through lower plate 250.

As best shown in FIGS. 3, 5, and 6, after passing through lower coldplate 250, unconditioned decoke sample fluid 101 encounters theplurality of separator members 270; unconditioned decoke sample fluid101 first encounters separators 270 of group 270-1, followed byseparators 270 of group 270-2, separators 270 of group 270-3, andfinally separators 270 of group 270-4. In general, unconditioned decokesample fluid 101 is free to flow through gas orifices 276 and/or drainports 277 in separator members 270. However, due to the inverted conegeometry of each separator member 270, as unconditioned decoke samplefluid 101 moves axially upward and encounters the lower-most separatormember 270, a substantial portion of unconditioned decoke sample fluid101 is urged to move radially outward by frustoconical lower surface272. As a result, the majority of unconditioned decoke sample fluid 101is generally guided or funneled towards gas orifices 276. After passingthrough gas orifices 276 of the lower-most separator member 270, theunconditioned decoke sample fluid 101 primarily flows through gasorifices 276 of the remaining separator members 270 since the relativelyhot unconditioned decoke sample fluid 101 inherently wants to riseaxially upward, and sample fluid 101 exits gas orifices 276 at an axiallocation above drain ports 277 and below gas orifices 276 of the nextsuccessive separator member 270.

Similar to lower plate 250, the temperature of separator members 270 isless than the temperature of unconditioned decoke sample fluid 101. Assample fluid 101 flows across separator members 270, thermal energy istransferred from the relatively warmer sample fluid 101 to therelatively cooling device separator members 270, and the temperature ofsample fluid 101 decreases. As the temperature of sample fluid 101decreases, contaminants 102 (i.e., water and heavy hydrocarbons) beginto coalesce and form relatively heavy liquid droplets, which begin todrain and flow under the force of gravity downward along surfaces 271,272 and through drain ports 277 in separating members 270. It should beappreciated that particulate matter in sample fluid 101 may becomecaptured in such droplets and flow axially downward through drain ports277 along with the droplets. Contaminants 102 flow along surfaces 271,272 and through drain ports 277 to lower plate 250, and then flowaxially downward through bores 255 in lower plate 250 and outlet 232back into the bulk decoke fluid stream. However, as contaminants 102coalesce and drain, the remaining unconditioned decoke sample fluid 101,which has been at least partially conditioned by the removal of somecontaminants 102, continues to migrate upward through gas orifices 276.

Referring now to FIGS. 3, 4, and 6, after migrating upward in separatorassembly 230 through separator members 270 via gas orifices 276,unconditioned decoke sample fluid 101 encounters baffles 260. Aspreviously described, the temperature of cooling fluid 221 in insulatingchamber 216, the temperature of separator assembly 230, and thetemperature of unconditioned decoke sample fluid 101 is lowest proximalupper end 230 b, baffles 260, and upper plate 250. In addition, sincegas orifices 276 of axially adjacent separator members 270 arepreferably disposed at different angular positions about axes 205, 215,235, as unconditioned decoke sample fluid 101 migrates upward throughseparator assembly 230, it is forced to change directions along atortuous path. As a result, the speed of unconditioned decoke samplefluid 101 gradually decreases and the pressure of unconditioned decokesample fluid 101 gradually increases as it migrates through separatorassembly 230 from inlet 231 to outlet 233. Thus, the pressure ofunconditioned decoke sample fluid 101 is greatest proximal outlet 233and upper end 230 b, which is also the region at which the temperatureof unconditioned decoke sample fluid 101 and separator assembly 230 arelowest. These conditions bring the molecules in unconditioned decokesample fluid 101 closer together, thereby enhancing the potential forcoalescence of any remaining contaminants 102. Thus, any contaminants inunconditioned decoke sample fluid 101 that did not coalesce on separatormembers 270 will coalesce as unconditioned decoke sample fluid 101encounters baffles 260 and upper plate 250 and flows through gasorifices 266 and bores 255, respectively, resulting in the finaltransition of unconditioned decoke sample fluid 101 into conditionedsample fluid 103. Upon exiting bores 255 of upper plate 250, conditionsample fluid 103 flows through outlet 233 of separator assembly 230.

The coalesced liquid contaminants 102 on the upper-most baffle 260 willtend to flow radially inward along surfaces 261, 262 drip onto the uppersurface 261 of the middle baffle 260. The coalesced liquid contaminants102 on the upper-most baffle 260 may also flow axially downward throughany gaps between rod 240 and upper-most baffle 260 (i.e., throughcentral bore 265). The coalesced liquid contaminants 102 on the lowertwo baffles 260 will tend to flow radially outward along surfaces 261,262 and drain through any gaps between conduit 234 and radially outersurfaces 264 into recess 278 of the upper-most separator member 270.Small quantities of the coalesced liquid contaminants 102 may also dripthrough gas orifices 266 into recess 278 of the upper-most separatormember 270. From recess 278 of upper-most separator member 270, liquidcontaminants 102 drain axially downward as previously described.

In the manner previously described, unconditioned decoke sample fluid101 is gradually transformed into conditioned sample fluid 103 by thegradual separation and removal of contaminants 102. Contaminants 102 arecontinuously separated and removed from unconditioned decoke samplefluid 101 as it migrates through separator assembly 230. Although samplefluid 101 is described as “unconditioned” as it moves through separatorassembly 230, and sample fluid 103 is described as “conditioned” uponexiting separator assembly 230, it should be appreciated that samplefluid 101 is gradually conditioned along its entire migration throughseparator assembly 230, and is at its most “conditioned” state uponexiting separator assembly 230 via outlet 233.

Referring now to FIG. 2, as previously described, system 300 acquiresreal-time information relating to (a) the temperature of cooling fluid221 at each inlet 213, outlet 214, and at different axial positionswithin insulating chamber 216; (b) the temperature of conditioned samplefluid 103 at outlet 233; (c) the status and position of each valve 321,322 (e.g., open, closed, etc.); and (d) the status of each coolingdevice 220 (e.g., on, off, etc.). In addition, by controlling valves 321and cooling devices 220 with actuators 331, 341, respectively, system300 is capable of controlling the temperature of cooling fluid 221 atinlets 213, which in turn allows system 300 to control the temperatureof cooling fluid 221 within insulating chamber 216 and outlet 214, aswell as control the temperature of sample fluids 101, 103. Stillfurther, by controlling valve 322 with actuator 332, system 300 iscapable of controlling the flow of conditioned sample fluid 103 flowingfrom separator 200 to the downstream equipment. Further, as previouslydescribed, the separation and removal of contaminants 102 fromunconditioned decoke sample fluid 101 results from the cooling ofunconditioned sample fluid 101, increasing the pressure of unconditionedsample fluid 101, and the coalescence of contaminants 102 into liquiddroplets. Accordingly, the temperature of unconditioned decoke samplefluid 101 as it migrates through separator assembly 230 is an importantfactor in the separation process—if the temperature of unconditioneddecoke sample fluid 101 is not sufficiently decreased in separatorassembly 230, then there may not be adequate separation and removal ofcontaminants 102. Without sufficient separation and removal ofcontaminants 102, equipment downstream of separator assembly 230 may befouled and/or damaged.

The temperature of cooling fluid 221 at inlets 213 is preferablymaintained between 38 and 42° F. This temperature range for coolingfluid 221 results in sufficient heat transfer from unconditioned samplefluid 101 to achieve an acceptable temperature for unconditioned samplefluid 101 (i.e., a temperature sufficiently low to achieve the desiredseparation and removal of contaminants 102). In particular, a coolingfluid inlet temperature between 38 and 42° F. results in a conditioneddecoke sample fluid outlet temperature between 60 and 90° F. If thetemperature of cooling fluid 221 at inlets 213, as measured by coolingfluid inlet temperature sensors 314, is too low, the degree of coolingprovided by cooling devices 221 may be decreased via actuators 341and/or one cooling device 221 may be completely turned off via itsactuator 341. On the other hand, if the temperature of cooling fluid 221at inlets 213, as measured by cooling fluid inlet temperature sensors314, is too high, the degree of cooling provided by cooling devices 221may be increased via actuators 341 and/or one or more additional coolingdevice(s) 221 may be turned on via its actuator 341. In some instances,the temperature of unconditioned fluid sample 101 and conditioned fluidsample 103 may still be too high. For example, the temperature of thebulk decoke fluid stream may unexpectedly spike, all cooling devices 221may be operating at maximum capacity but still cannot achieve thepreferred 38 and 42° F. cooling fluid inlet temperature, etc. If thetemperature of conditioned sample fluid 103 exiting separator 200, asmeasured by sensor 311, is sufficiently high, such that an insufficientquantity of contaminants 102 were separated and removed, then system 300can actuate valve 322 to the closed position with actuator 332, therebyrestricting and/or preventing conditioned sample fluid 103 from flowingto downstream equipment.

Referring still to FIG. 2, in many analytical devices that measureethylene and/or propylene yields from a conditioned decoke sample fluid(e.g., sample fluid 103), the measured yields (e.g., ethylene and/orpropylene CC per minute) are often slightly different than the actualyields in the cracking furnace. Specifically, as the temperature of thesample gas exiting the chamber varies, the measured analyte value willchange. If the fluid separator is operating at a temperature below setpoint, then the efficiency of the fluid separator has increased, thusresulting in the removal of additional heavy hydrocarbons or otherpossible impurities, such as water. The result is a volumetric increasein the measured analyte as reported by the process analyzer, which inthis case is ethylene and/or propylene. In contrast, if the fluidseparator is operating at a temperature above set point, then additionalheavy hydrocarbons or other possible impurities, such as water will makeup part of the overall sample to be measured by the process analyzer.Allowing the heavy hydrocarbons or impurities to exit the fluid samplerresults in a volumetric decrease of the measured analyte, as reported bythe gas chromatograph. In general, as the temperature of the conditioneddecoke sample fluid 103 increases, the measured ethylene and/orpropylene yields decreases, even though the actual ethylene and/orpropylene yields in the furnace may not have changed at all. To date, itis believe that this phenomenon has not been recognized or accounted forby plant operators, probably due in part to the fact that mostconventional sampling and conditioning devices do not measure or trackthe temperature of the conditioned decoke sample fluid temperatureexiting the conditioning device. However, embodiments described hereinoffer the potential to enable plant operators to account for suchdifferences between the measured ethylene and/or propylene yields andthe actual yields in the furnace. In particular, it is believed that forevery 1° F. increase in the temperature of conditioned decoke samplefluid 103 measured with sensor 311 at outlet 233, the measured ethyleneand/or propylene yields increase by 0.1% to 0.3%, and more specificallyincrease by 0.2%; and for every 1° F. decrease in the temperature ofconditioned decoke sample fluid 103 measured with sensor 311 at outlet233, the measured ethylene and/or propylene yields decrease by 0.1% to0.3%, and more specifically decrease by 0.2%. Accordingly, by measuringand tracking the temperature of conditioned decoke fluid sample 103 withsystem 300, plant operators can utilize these correlations to correctthe measured yields.

Embodiments described herein offer the potential for severalimprovements over existing sampling and conditioning devices. Forexample, embodiments described herein provide decreased dead volume ascompared most conventional sampling and conditioning devices. Ingeneral, the dead volume in a sampling and conditioning device refers tothe total volume of empty space within a separating device (e.g., totalempty space within conduit 234 of separator assembly 230). Therelationship between the lag time (i.e., time for a particular sample toflow through the device), the volumetric flow rate of the sampled fluidthrough the device, and the dead volume of the device is as follows:

${{Lag}\mspace{14mu} {Time}} \sim \frac{{Dead}\mspace{14mu} {Volume}}{{Volumetric}\mspace{14mu} {Flow}\mspace{14mu} {Rate}}$

Typically, the desired lag time is specified by the plant operators. Fora given lag time, as dead volume increases, the volumetric flow rate ofthe sampled fluid through the device increases. However, without beinglimited by this or any particular theory, as the volumetric flow rate ofthe sampled fluid through the device increases, the separatingefficiency and capacity of the device decreases (i.e., lower volumetricflow rate results in high pressure and more time within the device forcooling and coalescence). Consequently, it is generally preferred tohave a lower dead volume and lower volumetric flow rate to achieve aparticular lag time. In conventional sampling and conditioning deviceutilizing a series of steel mesh pads within a fluid conduit or pipe,the total dead volume is typically on the order of about three liters (3L). However, for a similarly sized device in accordance with embodimentsdescribed herein, the total dead volume is on the order of about one anda half liters (1.5 L).

In addition to decreased dead volume compared to similarly sizedconventional sampling and conditioning devices, embodiments describedherein provide increased surface area for coalescence of thecontaminants. Without being limited by this or any particular theory,the greater the available surface area in the sampling and conditioningdevice, the greater the coalescence and the greater the separationefficiency. The total surface area of the steel mesh pads provided inmost conventional devices is about 144 in.². However, the components ofa similarly sized device in accordance with the principles describedherein (e.g., separator members, baffles, plates, etc.) provide a totalsurface area of about 1,884 in.²

As previously described, maintenance and cleaning of most conventionalsampling and conditioning devices require a complete removal of thedevice from the upstream and downstream conduits and removal of thesteel mesh pads one-by-one. However, embodiments described herein offerthe potential for easier access and maintenance. In particular, outlet233 may be accessed by decoupling upper flange 203 from the adjacenthardware. An extractor tool may then be threaded onto upper end 240 b ofrod 240, and used to pull rod 240 and plates 250, baffles 260, spacers290, and separator members 270 coupled thereto out of conduit 234. Onceremoved from conduit 234, rod 240 and plates 250, baffles 260, spacers290, and separator members 270 may be inspected, cleaned, repaired,replaced, or combinations thereof, and then reinserted into conduit 234on rod 240.

Referring still to FIG. 2, unlike most conventional sampling andconditioning devices that provide no insight into the sampletemperature, the status of the sampling and conditioning device, or thetemperature of the cooling fluid, embodiments described monitor andtrack the temperature of cooling fluid at various points, thetemperature of conditioned sample fluid, the status of each coolingdevice, and the status of various valves controlling cooling fluid flowand conditioned sample fluid flow. In addition, by controlling suchvalves and cooling devices, embodiments described herein enable controlof the temperature of cooling fluid and the sample fluid.

Although embodiments shown and described herein are discussed in termsof conditioning a decoke fluid sample from a hydrocarbon crackingoperation to determine ethylene and/or propylene yields, in general,embodiments described herein may be used to condition other fluidsamples In particular, embodiments of system 100 may be used where highmoisture content, heavy hydrocarbons, particulate matter, and/orcombinations thereof may be present in the unconditioned fluid sampleand need to be removed prior to analysis. For example, embodimentsdescribed herein may be used to remove “green oil” from recycle gas oron a furnace decoke header to remove water and heavy particulates.

While preferred embodiments have been shown and described, modificationsthereof can be made by one skilled in the art without departing from thescope or teachings herein. The embodiments described herein areexemplary only and are not limiting. Many variations and modificationsof the systems, apparatus, and processes described herein are possibleand are within the scope of the invention. For example, the relativedimensions of various parts, the materials from which the various partsare made, and other parameters can be varied. Accordingly, the scope ofprotection is not limited to the embodiments described herein, but isonly limited by the claims that follow, the scope of which shall includeall equivalents of the subject matter of the claims.

1. A fluid sampling system, comprising: a fluid separator having acentral axis and including: an insulating sleeve; a separator assemblycoaxially disposed within the sleeve; and an annulus radially disposedbetween the sleeve and the separator assembly; wherein the separatorassembly includes a conduit, a support rod coaxially disposed within theconduit, and a plurality of separator members coupled to the support rodwithin the conduit.
 2. The fluid sampling system of claim 1, wherein theplurality of separator members are positioned one-above-the-other in anaxially extending stack within the conduit.
 3. The fluid sampling systemof claim 1, wherein each separator member extends radially between therod and the conduit; wherein each separator member extends axiallybetween an open upper end and a lower end; wherein each separator memberhas a frustoconical outer surface that tapers radially inward movingfrom the upper end to the lower end and a frustoconical inner surfacethat tapers radially inward moving from the upper end to the lower end;and wherein each separator member includes an inner recess extendingaxially from the open upper end.
 4. The fluid sampling system of claim3, wherein the plurality of separator members are arranged in a nestedwith the inner recess of each separator member receiving the lower endof the axially adjacent separator member.
 5. The fluid sampling systemof claim 4, wherein each separator member includes a gas orificeproximal the upper end and a drain port at the lower end.
 6. The fluidsampling system of claim 5, wherein each gas orifice has a radiusgreater than or equal to 1/64 in. and less than or equal to 1/16 in. 7.The fluid sampling system of claim 2, wherein each separator member isaxially spaced apart from each axially adjacent separator member.
 8. Thefluid sampling system of claim 5, wherein the gas orifice of eachseparator member is disposed at a different angular orientation aboutthe central axis than the gas orifice of each axially adjacent separatormember.
 9. The fluid sampling system of claim 5, wherein the lower endof each separator member includes a central throughbore that slidinglyreceives the support rod.
 10. The fluid sampling system of claim 9,further comprising a plurality of baffles disposed on the rod betweenthe plurality of separator members and an upper end of the rod, whereineach baffle comprises a dome-shaped disc having a concave surface and aconvex surface parallel to the concave surface, and a radially outersurface extending axially between the concave surface and the convexsurface.
 11. The fluid sampling system of claim 10, wherein the bafflesare arranged one-above-the other within the conduit, and wherein eachbaffle extends radially between the rod and the conduit.
 12. The fluidsampling system of claim 10, wherein each baffle is axially spaced apartfrom each axially adjacent baffle.
 13. The fluid sampling system ofclaim 12, wherein each baffle includes a gas orifice proximal theradially outer surface and a central through bore that receives thesupport rod.
 13. The fluid sampling system of claim 12, wherein theplurality of baffles comprises a first baffle axially positionedproximal the separator members, a second baffle axially positionedproximal the upper end of the support rod, and a third baffle axiallypositioned between the first baffle and the second baffle; wherein thefirst baffle and the second baffle are each oriented with the convexsurface facing upward, and wherein the second baffle is oriented withthe concave surface facing upward.
 15. The fluid sampling system ofclaim 10, further comprising a lower plate disposed about the supportrod proximal a lower end of the support rod, and an upper plate disposedabout the support rod proximal the upper end of the support rod.
 16. Thefluid sampling system of claim 15, wherein each plate extends betweenthe rod and the conduit and includes a planar upper surface, a planarlower surface that is parallel to the upper surface, a plurality ofthrough bores extending axially from the upper surface to the lowersurface, and a central through bore that receives the support rod. 17.The fluid sampling system of claim 1, wherein the fluid separatorextends axially from an upper end to a lower end; wherein the annulusincludes an inlet proximal the upper end and an outlet proximal thelower end; wherein the conduit includes an inlet at the lower end, anoutlet at the lower end, and an outlet at the upper end.
 18. The fluidsampling system of claim 17, wherein the insulating sleeve includes aplurality of axially spaced ports extending radially from the outersurface of the insulating sleeve to the annulus, and wherein onetemperature sensor is positioned in each port.
 19. The fluid samplingsystem of claim 17, further comprising a cooling device adapted to coola fluid, wherein the cooling device is in fluid communication with theinlet of the annulus.
 20. The fluid sampling system of claim 18, furthercomprising: a first valve adapted to control the flow of fluid from theoutlet of the conduit disposed at the upper end; a first actuatoradapted to control the first valve; a second valve adapted to controlthe flow of fluid through the inlet of the annulus; a second actuatoradapted to control the second valve; a first temperature sensorpositioned proximal the inlet of the annulus and adapted to measure thetemperature of the fluid flowing through the inlet of the annulus; and asecond temperature sensor positioned proximal the outlet of the conduitat the upper end and adapted to measure the temperature of a fluidflowing through the outlet of the conduit at the upper end.
 21. A systemfor removing contaminants from a sample fluid, comprising: a fluidseparator having a central axis and extending axially between an upperend and a lower end, the fluid separator including: an insulating sleeveaxially positioned between the upper end and the lower end; a separatorassembly coaxially disposed within the sleeve and extending between theupper end and the lower end, the separator assembly including an inletand an outlet; and an annulus radially disposed between the sleeve andthe separator assembly, wherein the annulus includes an inlet and anoutlet; a cooling device adapted to pump a cooling fluid through theinlet of the annulus; a monitoring and control system coupled to thefluid separator and including: a first temperature sensor proximal theoutlet of the separator assembly, the first temperature sensor adaptedto measure the temperature of a fluid flowing through the outlet of theseparator assembly.
 22. The system of claim 21, wherein the monitoringand control system further comprises a second temperature sensorproximal the inlet of the annulus, the first temperature sensor adaptedto measure the temperature of the cooling fluid flowing through theinlet of the annulus.
 23. The system of claim 22, wherein the monitoringand control system further comprises: a first valve adapted to controlthe flow of the fluid flowing through the outlet of the separatingassembly; and a first actuator adapted to control the first valve. 24.The system of claim 23, wherein the monitoring and control systemfurther comprises: a second valve adapted to control the flow of thecooling fluid through the inlet of the annulus; and a second actuatoradapted to control the second valve.
 25. The system of claim 24, whereinthe insulating sleeve further includes a plurality of axially spacedports, each port extending radially through the insulating sleeve to theannulus; and wherein the monitoring and control system further comprisesone temperature sensor disposed in each port and adapted to measure thetemperature of the cooling fluid flowing through the annulus.
 26. Thesystem of claim 24, wherein the separator assembly further comprises: aconduit coaxially disposed within the insulating sleeve and defining theinlet and the outlet of the separator assembly; a support rod coaxiallydisposed within the conduit; a plurality of separator members coupled tothe support rod, each separator member extending radially between thesupport rod and the conduit.
 27. The system of claim 26, wherein theplurality of separator members are axially positioned one-above-theother.
 28. The system of claim 27, wherein each separator member is aninverted cone having an open upper end and a lower end disposed axiallybelow the upper end; and wherein each separator member includes a gasorifice proximal the upper end and a drain port proximal the lower end.29. The system of claim 28, wherein each separator member includes aninner recess extending axially from the open upper end; and wherein theplurality of separator members are arranged in a nested with the innerrecess of each separator member receiving the lower end of the axiallyadjacent separator member.
 30. The system of claim 29, wherein theplurality of separator members includes a first set of separator membershaving a first number of the gas orifices, and a second set of separatormembers having a second number of the gas orifices, wherein the firstnumber and the second number are different.
 31. The system of claim 29,wherein the plurality of separator members includes: a first set of theseparator members consisting of four gas orifices; a second set of theseparator members consisting of three gas orifices; a third set of theseparator members consisting of two gas orifices; and a fourth set ofthe separator members consisting of one gas orifice.
 32. The system ofclaim 31, wherein the first set of the separating members is positionedaxially below the second set of the separating members; wherein thesecond set of the separating members is positioned axially below thethird set of the separating members; and wherein the third set of theseparating members is positioned axially below the fourth set of theseparating members.
 32. The system of claim 30, wherein the gas orificesin each of the first set of separator members each have a first radius,and wherein the gas orifices in each of the second set of separatormembers each have a second radius that is different than the firstradius.
 33. A method, comprising: (a) acquiring an unconditioned fluidsample from a bulk fluid stream; (b) providing a separator having acentral axis and comprising: an insulating sleeve; a conduit coaxiallydisposed within the insulating sleeve, wherein the conduit including aninlet and an outlet and is radially spaced apart from the insulatingsleeve; an annulus radially disposed between the insulating sleeve andthe conduit, wherein the annulus has an inlet; and a plurality ofseparator members disposed within the conduit; (c) flowing theunconditioned fluid sample through the inlet of the conduit; (d) flowinga cooling fluid through the inlet of the annulus; (e) separating acontaminant fluid from the unconditioned fluid sample in the separatorassembly to produce a conditioned sample fluid; (f) flowing theconditioned fluid through the outlet of the conduit; (g) measuring thetemperature of the conditioned sample fluid at the outlet of theconduit; and (h) analyzing the conditioned fluid sample to estimate ayield rate for a product in the bulk fluid stream.
 34. The method ofclaim 33, further comprising cooling the cooling fluid with a coolingdevice.
 35. The method of claim 34, further comprising maintaining thetemperature of the cooling fluid between 38° and 42° F. at the inlet ofthe insulating sleeve.
 36. The method of claim 35, further comprisingmeasuring the temperature of the cooling fluid at the inlet of theannulus.
 37. The method of claim 33, wherein (e) further comprises:flowing the unconditioned fluid sample through the conduit from theinlet of the conduit toward the outlet of the conduit; reducing thetemperature of the unconditioned fluid sample as the unconditioned fluidsample flows toward the outlet of the conduit; increasing the pressureof the unconditioned fluid sample as the unconditioned fluid sampleflows toward the outlet of the conduit; and coalescing the contaminantfluid on the surface of one or more separator members.
 38. The method ofclaim 37, wherein each separator member is an inverted cone having anopen upper end and a lower end disposed axially below the upper end; andwherein each separator member includes a gas orifice proximal the upperend and a drain port proximal the lower end.
 39. The method of claim 38,further comprising: draining the contaminant fluid through the drainport of one or more separator members to the inlet of the conduit;flowing the unconditioned sample fluid through the gas orifice n eachseparator member.
 40. The method of claim 38, wherein each separatormember includes an inner recess extending axially from the open upperend; and wherein the plurality of separator members are arranged in anested with the inner recess of each separator member receiving thelower end of the axially adjacent separator member.
 41. The method ofclaim 38, wherein each separator member has a number N of gas orifices;and wherein the number N of gas orifices of one separator member isdifferent than the number N of gas orifices of a different separatormember.
 42. The method of claim 33, further comprising: (i) remotelycontrolling the flow of the conditioned sample fluid through the outletof the conduit; and (j) remotely controlling the flow of the coolingfluid through the annulus.
 43. The method of claim 42, wherein (i)comprises restricting the flow of the conditioned sample fluid throughthe outlet of the conduit when the temperature of the conditioned samplefluid at the outlet exceeds a predetermined temperature.
 44. The methodof claim 43, wherein (j) comprises adjusting the flow of the coolingfluid through the annulus when the temperature of the cooling fluid atthe inlet of the insulator sleeve falls outside of a predeterminedtemperature range.
 45. The method of claim 44, wherein the predeterminedtemperature range is 38° to 42° F.
 46. The method of claim 33, furthercomprising adjusting the estimate of the yield rate for the product inthe bulk fluid stream based on the temperature of the conditioned fluidsample at the outlet of the conduit.
 47. The method of claim 46, whereinthe estimate of the yield rate of the product in the bulk fluid streamis increased between 0.1% and 0.3% for each 1° F. increase in thetemperature of the conditioned sample fluid at the outlet of theconduit; and wherein the estimate of the yield rate of the product inthe bulk fluid stream is decreased between 0.1% and 0.3% for each 1° F.decrease in the temperature of the conditioned sample fluid at theoutlet of the conduit.